EP0276055B1 - Methode zur Herstellung einer dünnen Folie aus einem verstärkten Harz - Google Patents

Methode zur Herstellung einer dünnen Folie aus einem verstärkten Harz Download PDF

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Publication number
EP0276055B1
EP0276055B1 EP88300097A EP88300097A EP0276055B1 EP 0276055 B1 EP0276055 B1 EP 0276055B1 EP 88300097 A EP88300097 A EP 88300097A EP 88300097 A EP88300097 A EP 88300097A EP 0276055 B1 EP0276055 B1 EP 0276055B1
Authority
EP
European Patent Office
Prior art keywords
sheet
fibre
reinforced
fibres
sheets
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP88300097A
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English (en)
French (fr)
Other versions
EP0276055A2 (de
EP0276055A3 (en
Inventor
Hajime Nishibara
Akira Morii
Mikio Hayashi
Taro Mihara
Muneharu Wada
Yasushi Chosokabe
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumitomo Chemical Co Ltd
Original Assignee
Sumitomo Chemical Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sumitomo Chemical Co Ltd filed Critical Sumitomo Chemical Co Ltd
Publication of EP0276055A2 publication Critical patent/EP0276055A2/de
Publication of EP0276055A3 publication Critical patent/EP0276055A3/en
Application granted granted Critical
Publication of EP0276055B1 publication Critical patent/EP0276055B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/04—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
    • B29C55/08—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique transverse to the direction of feed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/144—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/023—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets using multilayered plates or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/10—Cords, strands or rovings, e.g. oriented cords, strands or rovings
    • B29K2105/101—Oriented
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B29K2105/126—Whiskers, i.e. reinforcement in the form of monocrystals

Definitions

  • the present invention relates to a method of producing a thin fibre- reinforced resin sheet.
  • Synthetic resin or rubber sheets reinforced with carbon fibre, glass fibre, alumina fibre, aromatic polyamide fibre, etc. include prepregs of continuous fibre bundle sheets impregnated with thermo-setting resin, and sheet moulding compounds in which chopped strands are used. They are widely utilized for sports or leisure use such as fishing rods, golf shafts, etc., industrial materials, moulding materials for airplanes and cars, etc.
  • Thin prepreg sheets are disclosed in JP-A-165428/1982 and JP-A-74347/1983.
  • JP-A-11315/1985 discloses a method of producing thin prepreg sheets.
  • the regulation of the thickness of these sheets is by increase or decrease of the fibre weight per unit area (that is, the number of filaments per fibre bundle) or by change of the thickness of the fibre itself.
  • a fibre bundle is used which is composed of 1,000-2,000 filaments and the weight per unit length of which is 0.06-0.15 g/m.
  • EP-A-0195562 discloses a method of making a shaped product by sandwiching a fibre-reinforced thermoformable sheet between sheets of shaping polymer, and applying differential pressure across the thickness of the heated assembly to shape it.
  • the present invention is a method of producing a flat thin reinforced resin prepreg sheet which comprises stretching of a starting fibre-reinforced resin prepreg sheet in intimate contact with thermoplastic resin sheet on one or both faces thereof, the thermoplastic resin sheet(s) being stretchable by at least 1.5 times.
  • This method is capable of producing thin reinforced resin sheets having uniform mechanical and physical properties.
  • the reinforced resin sheets used as starting material in the present invention can be selected from those which are already well known and widely used.
  • SMC sheets sheets of chopped strand fibres treated with sheet moulding compound
  • resin sheets reinforced with whiskers include, for example, prepreg sheets having continuous fibres arranged unidirectionally, sheets of chopped strand fibres treated with sheet moulding compound (hereinafter referred to as SMC sheets), and resin sheets reinforced with whiskers.
  • These fibre-reinforced resin sheets used as starting material may be produced by any known method. These starting fibre-reinforced sheets usually have both faces coated with release paper or plastic film. The fibres of these sheets may be those conventionally used.
  • fibres examples include inorganic fibers such as glass, carbon and graphite fibres; ceramic fibres such as aluminous, boron, titania and silicon carbide fibres; organic fibres including natural fibres and synthetic fibres such as cellulosic, aromatic polyamide, polyester, polyamide, acrylic, polyethylene and polypropylene fibres; metal fibres such as stainless steel fibres; metal coated inorganic and organic fibres; ceramic-coated metal fibres, etc.
  • These fibres can be used alone or in combination of two or more kinds depending on the particular required properties, and may be used just as they are sold on the market.
  • the synthetic resins and rubbers used as matrices for the starting fibre-reinforced resin sheets can also be those well known and used for fibre-reinforced resins.
  • thermoplastic resins such as polyethylenes, polypropylenes, polymethylmethacrylates, polystyrenes (including high impact polystyrene), polyvinyl chlorides, ABS resins, styrene-acrylonirile copolymers, polyamides, polyacetals, polysulfones, polycarbonates, polyphenylene oxides, polyethersulfones, polyether ether ketones etc.; synthetic rubbers such as polybutadiene, polyisoprene, polychloroprene, styrene-butadiene copolymer (SBR), acrylonitrile-buta
  • thermoplastic resin sheets which are to be stretched together with the starting reinforced sheets are those that can be stretched more than 1.5 times in the stretching direction; these include, for example, sheets of high density polyetheylene, low density polyethylene, polypropylene, polyethylene terephthalate, polystyrene, polyvinyl chloride, polyvinyl alcohol, polyamide, polyethersulfone and polyether ether ketone, etc.
  • a thermoplastic resin sheet is used in intimate contact with one or both sides of the reinforced sheet.
  • thermoplastic resin sheet should be so selected that its tensile strength is larger than that of the starting reinforced sheet under the stretch processing conditions - i.e. stretch direction, stretch time, and stretch temperature.
  • the relevant tensile strength is the sum of that of both facing sheets.
  • the other face of the reinforced sheet may be stuck to a very thin and easily stretchable thermoplastic resin film, if necessary, for the purposes of prevention of sticking and surface protection.
  • One particular example of the invention uses an epoxy resin-impregnated and unidirectionally arranged prepreg sheet and a high density polyethylene sheet of the order of 50-300 ⁇ thick.
  • the resin of the starting reinforced sheet should have close adhesion to the thermoplastic resin sheet.
  • any release paper or plastic film on the surface is first peeled off and then the thermoplastic film is applied uniformly to the exposed surface.
  • the time between peeling off and application is short. Caution should be exercised so that air does not remain between the contacting surfaces.
  • the composite sheet is heated to a temperature at which the matrix resin of the starting reinforced sheet can exhibit its stickiness and a uniform compressive force is applied to the composite.
  • the composite sheet may be caused to pass between rollers heated to a prescribed temperature.
  • the heating at this time may also serve as the preheating for the stretching step.
  • gaps may be generated after stretching, if the ends of the said sheets are only abutted.
  • the end parts can be overlapped slightly to an extent of 0.5 mm, and the thermoplastic sheet is stuck to the overlapped sheets.
  • the stretching direction may be crosswise or lengthwise.
  • stretch is generally made under tension crosswise, that is, in the direction at right angles to the direction of the continuous fibers, or in a direction having a component at right angles to the fibre direction.
  • the stretching direction may be lengthwise and/or crosswise.
  • the fibres tend to become aligned with the stretching direction so that the mechanical strength of the sheet can become directional.
  • the matrix resin is a thermoplastic resin, molecular orientation can occur, so that the strength per thickness of the fibre-reinforced sheet can be increased.
  • thermoplastic resin films As regards the methods of stretching, it is possible to apply methods of producing monoaxially or biaxially stretched films from thermoplastic resin films. These include roll stretch methods wherein the sheet is made to pass successively between a plurality of rolls of differing diameter and rate of rotation whereby the sheet is stretched under tension; tenter stretch methods wherein both ends of the sheet are successively grasped and held by clip chains, by which tension is applied laterally to stretch it; and methods wherein said clip chains are moved successively on gradually spreading guide rails, by which tension is applied laterally or laterally and longitudinally to stretch the sheet.
  • roll stretch methods wherein the sheet is made to pass successively between a plurality of rolls of differing diameter and rate of rotation whereby the sheet is stretched under tension
  • tenter stretch methods wherein both ends of the sheet are successively grasped and held by clip chains, by which tension is applied laterally to stretch it
  • clip chains are moved successively on gradually spreading guide rails, by which tension is applied laterally or laterally and longitudinally to stretch the sheet.
  • the roll stretch method performs stretching in the longitudinal direction only. Therefore, the method can be continuously combined with application to the starting reinforced sheet of the thermoplastic resin sheet, which itself can be an extension of production of the starting reinforced sheet; the latter may instead be formed separately and supplied from the roll.
  • the sheet can be cut into pieces of a prescribed length less than the width of the roll. Then the cut pieces of sheet are turned and arranged crosswise and are stretched in the direction perpendicular to the fibres or in a direction having a component perpendicular to the fibres.
  • the sheet is first stretched in the lengthwise direction, and subsequently it is cut into pieces of a prescribed length as described above. Then the cut pieces are turned and arranged crosswise and stretched.
  • the apparatus for the roll stretch method can be of a type well-known for producing monoaxially stretched films as mentioned above, e.g. having a raw sheet fixing table followed by a combination rolls part and a winding part.
  • the combination rolls part can have preheating, stretch, annealing and cooling parts.
  • Each roll is set at a temperature suitable for the resin of each sheet.
  • the annealing part is used as necessity requires depending on the kind of matrix resin.
  • external heating may be applied by a hot air current or an electric heater.
  • the temperature at the stretch part is such as to allow the stretch of both sheets, that is to say, a temperature at which the resin or rubber of the starting reinforced sheet becomes sufficiently plastic and low in viscosity.
  • a temperature at which the resin or rubber of the starting reinforced sheet becomes sufficiently plastic and low in viscosity is equal to the temperature for producing the starting reinforced sheet or several (e.g.tens) °C lower than that temperature.
  • the stretch ratio is regulated by changing the peripheral speed of the rolls in the stretch part.
  • the thickness of the product sheet and the fibre content per unit area of the sheet are in inverse proportion to the change of the area of the sheet, so that these call be regulated by the stretch ratio.
  • stretch can be either crosswise, or in both crosswise and lengthwise directions, as mentioned previously.
  • the stretch ratio can be determined by the predetermined position of the clip chain guide rails.
  • this thin prepreg sheet When this thin prepreg sheet is used in combination with an ordinary prepreg sheet, one disposed over the other with their fibre directions at right angles, this combined sheet is effective in increasing the crush strength, flexural strength and compression strength of a cylindrical body such as a fishing rod, golf club shaft, etc. formed from such a sheet; when they are disposed with their fibres crossing obliquely, this combined sheet is effective in increasing the twisting strength.
  • the fibre-reinforced sheet is an SMC sheet or a sheet blended with whiskers, it is not only possible to easily produce a thinner sheet of various thicknesses or a very thin sheet, but also to produce a sheet for specific uses by arranging the internal reinforcing fibres unidirectionally so that the resulting sheet can have directionality in strength.
  • the matrix resin of the fibre-reinforced sheet is a thermoplastic resin
  • the sheet was observed with an optical microscope; the lengths of the gaps between fibres were measured and its maximum value and the linearity of the fibres were examined.
  • a pipe was formed from a combination with an ordinary prepreg sheet and the formed pipe was observed with a scanning type electron microscope; examination was made for voids in the cross-section and for the area of the voids if any, and also for wrinkles.
  • the stretching apparatus used was a monoaxial stretching apparatus having a raw sheet fixing table, six preheating rolls, five stretch rolls, an annealing roll, a cooling roll, and a winder.
  • the starting fibre-reinforced resin sheet was used a fibre-reinforced resin sheet, whose fibres were Carbon Fibre AS4 (produced by Hercules Corp.; modulus of elasticity 24 ton/mm2), and whose yarn was composed of 3,000 filaments/bundle.
  • the sheet was impregnated with a matrix resin which was a mixed epoxy resin of bisphenol A type and cresol novolac type.
  • This sheet was a prepreg sheet with unidirectionally arranged continuous fibres, a resin content of 45 weight %, a fibre weight per unit area of 80 g/m2, and 1 m in width and 15 m in length.
  • the prepreg sheet was cut into pieces of a length of 1.1 m, and 13 cut pieces were arranged to re-form a sheet with the fibres extending crosswise.
  • the preheating part of the monoaxial stretching apparatus was set at 100°C, the stretch part at 125°C, the annealing part at 125°C, and the cooling part at 40°C.
  • the composite raw sheet was caused to travel from the raw sheet fixing table onto the rolls rotated at a speed of 3 m/min in the preheating part, and at 24 m/min in the stretch part, and finally it was wound onto the winder to obtain a thin prepreg sheet 1.1 m wide and 100 m long and having a fibre weight per unit area of 10 g/m2.
  • Table 1 The results of evaluation are shown in Table 1.
  • Carbon Fibre IM6 product of Hercules Corp.; modulus of elasticity 30 ton/mm2
  • mixed epoxy resin of bisphenol A type and cresol novolac type whose fibre weight per unit area was 125 g/m2 and resin content was 34 weight %
  • a pipe shaped body was produced in the same way as in Example 1 except that a thin prepreg sheet having a fibre weight per unit area of 10 g/m2 produced in the same manner as the starting (unstretched) prepreg sheet of Example 1.
  • a thin prepreg sheet having a fibre weight per unit area of 10 g/m2 produced in the same manner as the starting (unstretched) prepreg sheet of Example 1.
  • the result of evaluation are shown in Table 1.
  • a thin prepreg sheet was produced as in Example 1 except that the continuous unidirectional fibres of the starting fibre-reinforced resin sheet were Carbon Fibre IM6 bundles containing 6000 fibres per bundle. The result of evaluation is shown in Table 1.
  • a thin prepreg sheet was produced as in Example 1 except that the continuous unidirectional fibres of the starting fibre-reinforced resin sheet were bundles of alumina fibres (product of Sumitomo Chemical Compamy, Ltd.; diameter 9 ⁇ ) containing 1,000 fibres/bundle, the fibre weight per unit area was 80 g/m2, and the resin content was 30 weight %.
  • alumina fibres product of Sumitomo Chemical Compamy, Ltd.; diameter 9 ⁇
  • the fibre weight per unit area was 80 g/m2
  • the resin content was 30 weight %.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)
  • Shaping By String And By Release Of Stress In Plastics And The Like (AREA)

Claims (3)

  1. Verfahren zum Herstellen einer flachen dünnen faserverstärkten Kunststoff-Prepreg-Schicht, die aufweist das Dehnen einer ursprünglichen faserverstärkten Kunststoff-Prepreg-Schicht in engem Kontakt mit einer thermoplastischen Kunststoffschicht auf deren einer oder beider Flächen, wobei die thermoplastische Kunststoffschicht(en) um wenigstens 1,5 mal dehnbar ist.
  2. Verfahren nach Anspruch 1, wobei die ursprüngliche verstärkte Prepreg-Schicht im wesentlichen in einer Richtung angeordnete Verstärkungsfasern hat.
  3. Verfahren nach Anspruch 1 oder 2, wobei die thermoplastische Kunststoffschicht(en) von höherer Gesamt-Zugfestigkeit ist(sind) als die ursprüngliche faserverstärkte Prepreg-Schicht.
EP88300097A 1987-01-23 1988-01-07 Methode zur Herstellung einer dünnen Folie aus einem verstärkten Harz Expired - Lifetime EP0276055B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP14629/87 1987-01-23
JP62014629A JPS63182133A (ja) 1987-01-23 1987-01-23 薄物の繊維強化樹脂シ−トの製造方法

Publications (3)

Publication Number Publication Date
EP0276055A2 EP0276055A2 (de) 1988-07-27
EP0276055A3 EP0276055A3 (en) 1989-12-13
EP0276055B1 true EP0276055B1 (de) 1993-07-28

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP88300097A Expired - Lifetime EP0276055B1 (de) 1987-01-23 1988-01-07 Methode zur Herstellung einer dünnen Folie aus einem verstärkten Harz

Country Status (4)

Country Link
EP (1) EP0276055B1 (de)
JP (1) JPS63182133A (de)
KR (1) KR880008871A (de)
DE (1) DE3882542D1 (de)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20030011492A (ko) * 2001-08-03 2003-02-11 (주)코스켐 관 연결용 밀봉 패드 연신 장치
JP6784493B2 (ja) * 2016-01-25 2020-11-11 株式会社Ｓｕｂａｒｕ ロアアーム
JP6750949B2 (ja) * 2016-01-26 2020-09-02 株式会社Ｓｕｂａｒｕ 繊維強化樹脂構造体の製造方法及び繊維強化樹脂構造体
JP6771196B2 (ja) * 2016-02-01 2020-10-21 パナソニックＩｐマネジメント株式会社 樹脂管およびその製造方法
JP6702220B2 (ja) * 2017-02-10 2020-05-27 トヨタ自動車株式会社 シートモールディングコンパウンドの製造方法
JP6874876B2 (ja) * 2020-03-09 2021-05-19 トヨタ自動車株式会社 シートモールディングコンパウンド

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1478576A (en) * 1974-07-31 1977-07-06 Nippon Petrochemicals Co Ltd Method for the manufacture of rolled sheets and films of thermoplastic resins
JPS57181829A (en) * 1981-05-06 1982-11-09 Oji Yuka Gouseishi Kk Manufacture of stretched film by composite polyolefine resin
US4532099A (en) * 1982-03-10 1985-07-30 Isamu Kaji Conductive structure and method of manufacture thereof
JPS58203177A (ja) * 1982-05-21 1983-11-26 株式会社クラレ ベルトおよびひもならびにその製造方法
EP0195562B1 (de) * 1985-03-21 1992-10-28 Imperial Chemical Industries Plc Verfahren zur Herstellung geformter Gegenstände aus verstärkten Verbundmaterialien

Also Published As

Publication number Publication date
EP0276055A2 (de) 1988-07-27
JPS63182133A (ja) 1988-07-27
EP0276055A3 (en) 1989-12-13
JPH0584730B2 (de) 1993-12-03
DE3882542D1 (de) 1993-09-02
KR880008871A (ko) 1988-09-13

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